HYOSUNG GF125 Service Manual
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HYOSUNG GF125 Service Manual

Hyosung gf125 motorcycle service manual
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GF
125
HYOSUNG MOTORS & MACHINERY INC.
SERVICE MANUAL
99000-94200

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Summary of Contents for HYOSUNG GF125

  • Page 1 HYOSUNG MOTORS & MACHINERY INC. SERVICE MANUAL 99000-94200...
  • Page 2 This manual contains up-to-date information at the time of its issue. Latermade modifications and changes will be explanied to each HYOSUNG distributor in respective markets, to whom you are requested to make query about updated information, if any. HYOSUNG MOTORS & MACHINERY INC.
  • Page 3 GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES SERVICING ENGINE FUEL AND LUBRICATION SYSTEM ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATION...

  • Page 5: Table Of Contents

    GENERAL INFORMATION CONTENTS SERIAL NUMBER LOCATIONS FUEL AND OIL RECOMMENDATIONS BREAK-IN PROCEDURE SPECIAL FEATURES SPECIAL MATERIALS PRECAUTIONS AND GENERAL INSTRUCTIONS SPECIFICATIONS...

  • Page 6: Serial Number Locations

    1-1 GENERAL INFORMA TION SERIAL NUMBER LOCATIONS ENGINE OIL Be sure that the engine-oil you use comes under API The frame serial number ① is stamped on the rear end classification of SF or SG and that its vicosity rating is of the frame.

  • Page 7: General Informa Tion

    GENERAL INFORMA TION 1-2 SPECIAL FEATURES HYOSUNG GF 125 is a improved model that has been revised from 2 valve evgine of GF 125 to 4 valve engine and has much more developed features as follows. 1. IMPROVEMENT OF ENGINE POWER AT MIDDLE AND LOW SPEEDS...
  • Page 8 1-3 GENERAL INFORMA TION 3. CLUTCH MISSION The Primary Gear Ratio is improved from 3.47 to 3.50 in order to increase rotation. For improving CLUTCH durability while long distance driving, CLUTCH DAMPER is changed from rubber to steel Spring type. 4.
  • Page 9 GENERAL INFORMA TION 1-4 IGNITION SYSTEM DESCRIPTION The GF 125 Engine is equipped with a new type ignition system. This new system further reduces timing fluctuations. It has an “ignition timing control circuit”wich accurately controls the advance curve and maintains consistent timing independent of high RPM fluctuation, magnetic force, temperature, and air gap.
  • Page 10 1-5 GENERAL INFORMA TION Θ 360� Pick-up Coil Current ① Signal current to SCR Engine speed Below N Θ ② Between N and N Θ ③ Over N Fig. 2 Θ Engine speed(r/min) Fig. 3...

  • Page 11: Three

    GENERAL INFORMA TION 1-6 SPECIAL MATERIALS The materials listed below are needed for maintenance work on the GF 125 and should be kept on hand for ready use. These items supplement such standard materials as cleaning fluids, lubricants, emery cloth and the like. How to use them and where to use them are described in the text of this manual.

  • Page 12: General Informa Tion

    1-7 GENERAL INFORMA TION Material part part page page ● 2nd drive gear 3-42 ● Starter clutch allen bolt 3-51 THREAD LOCK SUPER “1303B” 99000-32030 ● Front fork damper rod bolts 6-10 THREAD LOCK CEMENT 99000-32040 ● Countershaft bearing 3-42 retainer screws ●...

  • Page 13: Precautions And General Instructions

    To replace any part of the machine, use a genuine HYOSUNG replacement part. Imitation parts or parts sup- plied from any other source than HYOSUNG if used to replace HYOSUNG parts, can reduce the machine’ s per- formance and, even worse, could induce costly mechani-...

  • Page 14: Specifications

    1-9 GENERAL INFORMA TION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ………………………………………………………… 1,968㎜ Overall width…………………………………………………………… 763㎜ Overall height ………………………………………………………… 1,073㎜ Wheel base …………………………………………………………… 1,292㎜ Ground clearance……………………………………………………… 195㎜ Dry mass ……………………………………………………………… 125㎏ ENGINE Type …………………………………………………………………… Four-strock, air-cooled, OHC Number of cylinder …………………………………………………… 1 Bore ……………………………………………………………………...
  • Page 15 GENERAL INFORMA TION 1-10 ELECTRICAL Ignition type …………………………………………………………… CDI TYPE Ignition timing ………………………………………………………… 15�B.T.D.C. below 2,250r/min and 35�B.T.D.C. above 4,000r/min Spark plug……………………………………………………………… C8EH-9 Battery ………………………………………………………………… 12V9Ah Headlight ……………………………………………………………… 35/35W Tail/Brake light………………………………………………………… 10/5W×2 Turn signal light ……………………………………………………… 10W Neutral indicator light ………………………………………………… 3W High beam indicator light ……………………………………………...

  • Page 16: Periodic Maintenance And

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES CONTENTS PERIODIC MAINTENANCE SCHEDULE………………………………………………… 2- 1 MAINTENANCE PROCEDURES………………………………………………………… 2- 3 BATTERY ………………………………………………………………………… 2- 3 CYLINDER HEAD NUTS , CYLINDER NUTS, EXHASUST PIPE BOLTS AND NUTS ……………………………………………………………… 2- 4 AIR CLEANER ELEMENT ………………………………………………………… 2- 5 VALVE CLEARANCE ……………………………………………………………… 2- 6 COMPRESSION PROSSURE ………………………………………………………...

  • Page 17: Periodic Maintenance Schedule

    2-1 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions. PERIODIC MAINTENANCE CHART ENGINE Interval...
  • Page 18 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-2 LUBRICATION CHART The maintenance schedule, which follows, is based on this philosophy. It is timed by odometer indication, and is calculated to achieve the ultimate goal of motorcycle maintenance in the most ecomomical manner. Interval Interval and Every 5,000km Every 10,000km...

  • Page 19: Maintenance Procedures

    2-3 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES MAINTENANCE PROCEDURES This section describes the service procedures for each section of periodic Maintenance. BATTERY Inspect Initial 1,000km and Every 5,000km ● The battery must be removed to check the electrolyte level and specific gravity. ●...

  • Page 20: Bolts And Nuts

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-4 CYLINER HEAD NUTS, CYLINDER NUTS, EXHAUST PIPE BOLTS AND NUTS ① Inspect Initial 1,000km and Every 5,000km CYLINDER HEAD NUTS ● Remove the seat and fuel tank. (Refer to page 3-2) ● Remove the cylinder head cover. (Refer to page 3-7) ●...

  • Page 21: Air Cleaner Element

    2-5 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES AIR CLEANER ELEMENT Clean Every 3000km If the air cleaner is clogged with dust, intake resistance will be increased with a resultant decrease in power out- put and an increase in fuel consumption. Check and clean the element in the following manner.

  • Page 22: Valve Clearance

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-6 VALVE CLEARANCE Inspect Initial 1,000km and Every 5,000km Excessive valve clearance results in valve noise and insuf- ① ficient valve clearance results in valve damage and reduced power. At the distances indicated above, check and adjust the clearance to the following specification The procedure for adjusting the valve clearance is as fol- ②...

  • Page 23: Spark Plug

    2-7 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES SPARK PLUG Inspect Initial 1,000km and 5,000km Replace Every 10,000km Remove the carbon deposits with a wire or pin and adjust the spark plug gap to 0.7-0.8mm, measuring with a thickness gauge. When removing carbon deposits, be sure to ovserve the appearance of the plug, noting the color of the carbon deposits.

  • Page 24: Fuel Line

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-8 FUEL LINE Inspect Initial 1,000km and Every 5,000km Replace every four years. Inspect the fuel line and connections for damage and fuel leakage. If any defects are found, the fuel line must be replaced. FUEL STRAINER Change Initial 1,000km Every 10,000km If the fuel strainer is dirty with sediment, fuel will not flow...

  • Page 25: Engine Oil Filter

    2-9 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES ENGINE OIL FILTER �Replace Initial 1,000km and Every 5,000km Replace the oil filter in the following manner. ● Drain engine oil by removing the drain plug. ● Remove the three screws securing the filter cap. ●...

  • Page 26: Carburetor

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-10 CARBURETOR Inspect Initial 1,000km and Every 5,000km ① IDLING ADJUSTMENT NOTE: Make this adjustment when the engine is hot. ● Start up the engine and set its speed at anywhere between 1400 and 1500r/min by turning throttle stop screw ①.

  • Page 27: Drive Chain

    2-11 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES DRIVE CHAIN Inspect and Clean Every 1,000km DRIVE CHAIN Visually inspect the drive chain for the belos listed possi- ble malconditions. (Lift the rear sheel by placing the cen- ter stand, and turn the rear wheel slowly by hand, with the transmission in NEUTRAL.) Inspect for: 1.

  • Page 28: Brakes

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-12 BRAKES Inspect Initial 1,000km and Every 5,000km Replace the hoses Every four years Change fluid hoses Every two years FRONT BRAKE Brake fluid level ● Support the motorcycle body on the center stand, and place the handlebars straight.
  • Page 29 2-13 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full brak- ing performance of the caliper brake.

  • Page 30: Tires

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-14 REAR BRAKE This is effected by turning the brake pedal stopper ①. Be sure to tighten the lock nut securely after setting the bolt. After adjusting the rear brake height, adjust the brake pedal traval. First set the pedal at position for comfort- able riding by turning the brake pedal stopper ①, and then adjust the free travel ②...

  • Page 31: Steering

    2-15 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES STEERING ② Inspect Initial 1,000km and Every 5,000km ① ① Steering stem bearings should be adjusted properly for smooth turning of the handlebars and safe running. Steering which is too stiff prevents smooth movement of handlebars.
  • Page 32 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-16 CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS Inspect Initial 1,000km and Every 5,000km The nuts and bolts listed are important parts, and they must be in good condition for safety. They must be retightened, as necessary, to the specified torque with a torque wrench. Tightening torque ITEM N∙m...
  • Page 33 2-17 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES ⑧ ⑤ ⑦ ⑪ ⑩ ⑨...

  • Page 34: Servicing Engine

    SERVICING ENGINE CONTENTS COMPRESSION PRESSURE AND OIL PERSSURE ……………………………………… 3- 1 ENGINE REMOVE AND REMOUNTING ……………………………………………… 3- 2 UPPER END COMPONENTS DISASSEMBLY ………………………………………… 3- 7 UPPER END COMPONENTS INSPECTION AND SERVICING ………………………… 3-11 UPPER END COMPONENTS REASSEMBLY ………………………………………… 3-21 LEFT ENGINE DISASSEMBLY ………………………………………………………… 3-28 RIGHT ENGINE DISASSEMBLY ………………………………………………………...

  • Page 35: Compression Pressure And Oil Perssure

    3-1 SERVICING ENGINE COMPRESSION PRESSURE AND OIL PRESSURE COMPRESSION PRESSURE OIL PRESSURE Install the oil pressure gauge in the position shown in the NOTE: illustration. ● Before inspecting for compression pressure, Warm up the engine as follows: make sure that the cylinder head nuts and ●...

  • Page 36: Engine Remove And Remounting

    SERVICING ENGINE 3-2 ENGINE REMOVAL AND REMOUNTING ENGINE REMOVAL Before taking the engine out of the frame, thoroughly clean the engine with a suitable cleaner. The proce- dure of engine removal is sequentially explained in the following steps. ● Take off the seat by opening the seat lock. ●...
  • Page 37 3-3 SERVING ENGINE ● Take off the clutch cable by removing the clutch release arm bolt. ● Disconnect the lead wire of starter motor. ● Take off the spark plug cap. ● Disconnect the couplers and lead wire.
  • Page 38 SERVICING ENGINE 3-4 ● Take off the breather pipe. ● Remove the carburetor with intake pipe loosening the intake bolts and carburetor clamp screw. ● Remove the engine sprocket cover. ● Loosen the rear axle nut and chain adjuster nuts. ●...
  • Page 39 3-5 SERVICING ENGINE ● Disconnect the ground wire from the crankcase. ● Take off the gear shift lever by removing the bolt. ● Remove the exhaust pipe bolts and muffler mounting bolt, then take off the muffler. ● Remove the swing arm pivot nut, and remove the shaft ①.
  • Page 40 SERVICING ENGINE 3-6 ENGINE REMOUNTING ● After remounting the engine, following adjustments are necessary. The engine can be mounted in the reverse order of ● Throttle cable (Page : 2-10) removal. ● Clutch cable (Page : 2-10) ● Temporarily fasten the engine mounting spacer before ●...

  • Page 41: Upper End Components Disassembly

    3-7 SERVICING ENGINE UPPER END COMPONENTS DISASSEMBLY CYLINDER HEAD COVER-CAMSHAFT ● Bring the piston to top dead center. NOTE: W h e n r e m o v i n g c y l i n d e r h e a d c o v e r , p i s t o n must be at top dead center on compression stroke.
  • Page 42 SERVICING ENGINE 3-8 ● Remove camshaft center bolt. NOTE: This is a left-hand thread nut. ● Remove C-ring③, cam sprocket② and camshaft①. ① CAUTION: ③ Do not drop camshaft drive chain, key and sprocket ② into the crankcase. CAMSHAFT HOLDER ●...
  • Page 43 3-9 SERVICING ENGINE ● Install the bolt by the rocker arm shaft and pull out the rocker arm shaft. CYLINDER HEAD ● Loosen the cylinder head nuts, then detach the cylin- der head. NOTE: If it is difficult to remove the cylinder head, gently pry it off while tapping the finless portion of the cylinder head with a plastic hammer.
  • Page 44 SERVICING ENGINE 3-10 ● Remove oil seal, using long-nose pliers. NOTE: Removed oil seal should be replaced with a new one. ● Take out the spring seat. CYLINDER ● Remove cylinder base nuts and cylinder. CAUTION: If tapping with plastic hammer is necessary, do not break the fins.

  • Page 45: Upper End Components Inspection And Servicing

    3-11 SERVICING ENGINE UPPER END COMPONENTS INSPECTION AND SERVICING CAMSHAFT HOLDER DISTORTION After removing oil from the fitting surface of the camshaft holder, place the camshaft holder on a surface plate and check for distortion with a thickness gauge. Check points are shown in Fig.
  • Page 46 SERVICING ENGINE 3-12 CAMSHAFT CAM WEAR Worn-down cams are often the cause of mistimed valve operation resulting in reduced output power. The limit of cam wear is specified for both intake and exhaust cams in terms of cam height �, which is to be measured with a micrometer.
  • Page 47 3-13 SERVICING ENGINE VALVE HEAD RADIAL RUNOUT Place the dial gauge at right angles to the valve head, and measure the valve head radial runout. If it measures more than limit, replace the valve. Service limit 0.03㎜ VALVE GUIDE-VALVE STEM CLEARANCE Measure the clearance in two directions, “X”...
  • Page 48 SERVICING ENGINE 3-14 VALVE GUIDE INSTALLATION ② ● Re-finish the valve guide holes in cylinder head with a ① 10.5㎜ reamer ① and handle ②. 09916H34575 10.5㎜ reamer Handle 09916-34541 ● Fit a ring to each valve guide. Be sure to use new rings and valve guides.
  • Page 49 3-15 SERVICING ENGINE ● Lubricate each seal, and drive them into position with the valve stem seal installer ①. CAUTION: ① Do not reuse the oil seals. Valve guide installer and 09916-44910 stem seal installer VALVE SEAT WIDTH ● Coat the valve seat with prussian blue uniformly. Fit the valve and tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact.
  • Page 50 SERVICING ENGINE 3-16 1. Insert with a slight rotation, the solid pilot that gives a snug fit. The shoulder on the pilot should be about 10 ㎜ from the valve guide. 2. Using the 45� cutter, descale and cleanup the seat with one or two turns.
  • Page 51 If the limit indicated below is exceeded by the free length reading or if the measured force does not fall within the range specified, replace with a HYOSUNG spring as a set. Valve spring free length Spring Service limit 41.65㎜...
  • Page 52 SERVICING ENGINE 3-18 PISTON DIAMETER Using a micrometer, measure the piston outside diameter at the place 15㎜ from the skirt end as shown in Fig. If the measurement is less than the limit, replace the pis- ton. 09900-20203 Micrometer(50~75㎜) Service limit 56.880㎜...
  • Page 53 3-19 SERVICING ENGINE Piston ring groove width Piston ring Standard 1.01~1.03㎜ 1.01~1.03㎜ 2.01~2.03㎜ PISTON RING FREE END GAP AND PISTON RING END GAP Before installing piston rings, measure the free end gap of each ring using vernier calipers. Next, fit the ring in the cylinder, and measure each ring end gap using a thickness gauge.
  • Page 54 SERVICING ENGINE 3-20 OVERSIZE RINGS ● Oversize piston rings The following two types of oversize piston rings are used. They bear the following identification numbers. Piston ring 0.5㎜ 1.0㎜ ● Oversize oil rings The following two types of oversize oil ring are used. They bear the following identification marks.

  • Page 55: Upper End Components Reassembly

    3-21 SERVICING ENGINE UPPER END COMPONENTS REASSEMBLY OIL RING Install spacer ① into the bottom ring groove first. Then Oil ring install both side rails ②, one on each side of the spacer. The spacer and side rails do not have a specific top or bottom when they are new.

  • Page 56: Piston Pin

    SERVICING ENGINE 3-22 PISTON The following are reminders for piston installation: ● Rub a small quantity of HYOSUNG MOLY PASTE onto the piston pin. ● Place a clean rag over the cylinder base to prevent piston pin circlip from dropping into crankcase, and then fit the piston pin circlip with long-nose pliers.
  • Page 57 3-23 SERVICING ENGINE VALVE AND SPRING ● Insert the valves, with their stems coated with (HYOSUNG MOLY PASTE) all around and along the full stem length without any break. Similarly oil the lip of the stem seal. 99000-25140 Hyosung moly paste...
  • Page 58 SERVICING ENGINE 3-24 ● Fit the cylinder head. ● Tighten the cylinder base nuts ①. ● Tighten the cylinder head base nuts ②. Cylinder base nuts 60~80㎏∙㎝ tightening Torque ② NOTE: When mounting the cylinder, after attaching ① camshaft drive chain, keep the camshaft drive c h a i n t a u t .

  • Page 59: Rocker Arm Shaft

    3-25 SERVICING ENGINE ● Install the camshaft lock C-ring ①. ① CAMSHAFT HOLD ● Apply HYOSUNG MOLY PASTE to the rocker arm shafts. ● Install the rocker arm spring, rocker arm and inserting the shafts. Groove ● Fit the two dowel pins to the camshaft holder.
  • Page 60 SERVICING ENGINE 3-26 ● Fit the two dowel pins and install the camshaft holder ①. ① � ● Tighten the camshaft holder nuts to the specified. Tightening torque 250~290㎏∙㎝ CHAIN TENSIONER ● Remove the bolt and spring at the tensioner body. ●...
  • Page 61 3-27 SERVICING ENGINE VALVE CLEARANCE ● After tightening the camshaft holder lock nuts, check and adjust the valve clearance. Valve clearance specifications IN. and EX. 0.10~0.13㎜ NOTE: Valve clearance is to be checked when the engine is cold. Both the intake and exhaust valves must be checked and adjusted when the piston is at T o p - D e a d - C e n t e r ( T D C ) o f t h e c o m p r e s s i o n stroke.

  • Page 62: Left Engine Disassembly

    SERVICING ENGINE 3-28 LEFT ENGINE DISASSEMBLY MAGNETO ROTOR ● Remove gear change lever bolt ①. ② ● Remove the frame down tube ② by removing the mounting bolts. ● Remove sprocket cover bolts and detach sprocket ① cover. ● Remove magneto cover bolts and detach magneto cover.
  • Page 63 3-29 SERVICING ENGINE ● Remove magneto rotor and key. 09930-30162 Rotor remover ● Remove starter clutch gear. ● Remove stator screw by using the impact drive and detach stator. ● Remove roller ①, spring ② and push piece ③ from stater clutch.

  • Page 64: Right Engine Disassembly

    SERVICING ENGINE 3-30 ● Clamp the rotor with a vise taking care not to damage it and remove the three allen bolts using the 5mm “L” type hexagon wrench. 09900-00401 “L” type hexagon(5mm) GEAR POSITION SWITCH ● Remove the gear position indicator switch by removing the screws.
  • Page 65 3-31 SERVICING ENGINE ● Remove clutch cover bolts and oil filter cap bolts, and detach clutch cover by tapping with a plastic hammer. ● Remove clutch spring mounting bolts diagonally while holding the primary driven gear, and remove clutch pressure plate. ●...
  • Page 66 SERVICING ENGINE 3-32 ● Remove oil pump driven gear, then remove primary drive gear and key. OIL PUMP ● Remove oil pump mounting screws and take off oil pump body. GEAR SHIFTER ② ③ ④ ● To remove cam driven gear, first remove gear shifting ①...
  • Page 67 3-33 SERVICING ENGINE LOW END COMPONENTS DISASSEMBLY CRANK CASE ● Remove sump filter cap and neutral cam stopper. ● Remove sump filter. ● Remove crankcase securing bolts. ● Separte the crankcase into 2 parts, right and left with crankcase separating tool. 09920-13120 Crankcase separating tool ●...
  • Page 68 SERVICING ENGINE 3-34 TRANSMISSION ● Remove gear cam stopper spring. ● Draw out gear shifting fork shafts and take off forks. ● Remove clusters of gears and gear shifting cam. KICK STARTER SHAFT ● Remove circlip, spring guide and return spring. ●...
  • Page 69 3-35 SERVICING ENGINE CRANKSHAFT ● Remove crankshaft by using crankcase remover. 09920-13111 Crankshaft remover OIL SEAL AND BEARING ● Remove retainer, oil seals and bearings. 09913-50121 Oil seal remover...

  • Page 70: Lower End Components Disassembly

    SERVICING ENGINE 3-36 LOWER END COMPONENTS INSPECTION AND SERVICING CONROD DEFLECTION AND CONROD BIG END SIDE CLEARANCE Wear on the big end of the conrod can be estimated by checking the movement of the samll end of the rod. This method can also check the extent of wear on the parts of the conrod’...
  • Page 71 3-37 SERVICING ENGINE CLUTCH DRIVE PLATE Measure the thickness and claw width of each drive plate with vernier calipers. Replace drive plates found to have worn down to the limit. 09900-20101 Vernier callipers Item Standard Limit Thickness 2.9-3.1mm 2.6mm Claw width 11.8-12.0mm 11.0mm Checking thickness...

  • Page 72: Three

    SERVICING ENGINE 3-38 CLUTCH RELEASE BEARING Inspect the release bearing for any abnormality, parti- calarly cracks, to decide whether it can be reused or should be replaced. Smooth engagement and disengagement of the clutch depends much on the condition of this bearing. SHIFTING FORK AND GEAR Using a thickness gauge, check the shifting fork clearance in the groove of its gear.
  • Page 73 3-39 SERVICING ENGINE PRIMARY DRIVEN GEAR ① Primary driven gear is composed as shown. ③ ② ① Primary driven gear ④ Rivet ② Damper ⑤ Clutch housing ④ ③ Plate ⑤ If the internal damper wears, play is generated between gear and housing, causing abnormal noise.

  • Page 74: Lower End Components Reassembly

    SERVICING ENGINE 3-40 LOWER END COMPONENTS REASSEMBLY CRANKSHAFT ● Decide the between the webs referring to the figure ● When mounting the crankshaft in the crankcase, it is below when rebuilding the crankshaft. necessary to pull its left end into the crankcase. STD width between webs 53.0±0.1mm 09910-32812...
  • Page 75 3-41 SERVICING ENGINE CAUTION: Never fit the crankshaft into the crankcase by striking it with a plastic hammer. A l w a y s u s e t h e s p e c i a l t o o l , o t h e r w i s e crankshaft alignment accuracy will be affect - TRANSMISSION...
  • Page 76 SERVICING ENGINE 3-42 Washers and circlips thickness. � 1.2mm � 1.0mm � 1.0mm � 0.5mm � 1.0mm NOTE: When reassembling the bearing retainer, apply a small quantity of THREAD LOCK “1342” to the threaded parts of the bearing retainer screws. In reassembling the transmission, attention must be given to the locations and positions of washers and cir- clips.
  • Page 77 3-43 SERVICING ENGINE GEAR SHIFTING CAM AND FORK ● Fit gear shifting cam on the crankcase. Position the cam as shown in Fig. so that the gear shifting fork can be installed easily.
  • Page 78 SERVICING ENGINE 3-44 NOTE: Two kinds of gear shifting forks, ① and ②, a r e u s e d . T h e y r e s e m b l e s e a c h o t h e r v e r y closely in external appearance and configura - tion.

  • Page 79: Oil Seals

    3-45 SERVICING ENGINE ● When fitting the kick starter to the shaft, be sure to align the punched marks. ● ● ● Fit spring and washer on the shaft. Then, insert the kick starter shaft into crankcase. Engage pawl ① of kick starter guide ②.
  • Page 80 SERVICING ENGINE 3-46 ● After the crankcase bolts have been tightened, check if driveshaft and countershaft rotate smoothly. ● If a large resistance is felt to rotation, try to free the shafts by tapping the driveshaft or countershaft with a plastic hammer as shown in Fig.

  • Page 81: Right Engine Reassembly

    3-47 SERVICING ENGINE RIGHT ENGINE REASSEMBLY KICK START DRIVE GEAR AND IDLE GEAR ● Install kick starter idle gear and drive gear. 09900-06107 Snap ring pliers GEAR SHIFTING CAM DRIVEN GEAR When installing the gear shifting pawls into the cam driv- en gear.
  • Page 82 SERVICING ENGINE 3-48 PRIMARY DRIVE GEAR AND OIL PUMP ● Fit key in the solt on the crankshaft, and install the primary drive gear. ● Before mounting the oil pump, apply engine oil to the sliding surfaces of the case, outer rotor, inner rotor and shaft.
  • Page 83 3-49 SERVICING ENGINE CLUTCH ● Install the clutch camshaft by positioning the face to right side. ● Install the oil seal by using 17mm socket. ● Tighten the oil seal retainer screw.
  • Page 84 SERVICING ENGINE 3-50 Assemble the clutch, in the reverse order of disassembly. Pay attention to the following points. ● When inserting spacer on countershaft, apply a small quantity of engine oil to both inside and outside of the spacer. ● Tighten clutch sleeve hub nut using the special tool to the specified torque.

  • Page 85: Left Engine Reassembly

    3-51 SERVICING ENGINE LEFT ENGINE REASSEMBLY SRATOR Apply a small quantity of THREAD LOCK “1342”to the threaded parts of screws. 99000-32050 Thread lock “1342” STARTER CLUTCH Locate the shim ① to the proper position. ① ● Apply THREAD LOCK SUPER “1303B”to allen bolts and tighten with specified torque.
  • Page 86 SERVICING ENGINE 3-52 99000-32100 Thread lock super “1305” 09930-44511 Rotor holder Tightening torque 30-40N∙m(3.0-4.0kg∙m) STARTER IDLE GEAR AND MOTOR ● Install the starter idle gear. ● Install the starter motor. DRIVESHAFT OIL SEAL AND ENGINE SPROCKET CAUTION: Oil seal ● Always replace the driveshaft oil seal with a new one every disassembly to prevent oil leak- O-ring age.
  • Page 87 3-53 SERVICING ENGINE ● Tighten the engine sprocket nut to the specified torque and bend up the washer. 09930-40113 Rotor and sprocket holder Tightening torque 80-100N∙m(8.0-10.0kg∙m) GEAR POSITION SWITCH ● Install gear position switch.
  • Page 88 FUEL AND LUBRICATION SYSTEM CONTENTS FUEL COCK ………………………………………………………………………… 4- 1 CARBURETOR ………………………………………………………………………… 4- 2 SPECIFICATION ………………………………………………………………… 4- 2 REMOVAL, DISASSEMBLY AND INSPECTION ………………………………… 4- 3 REASSEMBLY AND REMOUNTING …………………………………………… 4- 7 LUBRICATION SYSTEM ……………………………………………………………… 4-11...

  • Page 89: Fuel Cock

    4-1 FUEL AND LUBRICA TION SYSTEM FUEL COCK ● Unscrew the fuel cock securing bolts, and take off the fuel cock assemble. Gasket CLEANING Rust from the fuel tank tends to build up in the filter, which, when the filter has been neglected for a long peri- od, inhibits the flow of fuel.

  • Page 90: Carburetor

    FUEL AND LUBRICA TION SYSTEM 4-2 CARBURETOR SPECIFICATIONS ITEM SPECIFICATION ITEM SPECIFICATION Carburetor type PD 18 F Needle jet (N. J.) J6TC-3rd Bore size 24mm Pilot jet (P.J.) I.D. No. 93 BO By pass (B.P.) 2.9, ∅1.0, ∅0.9 Idle r/min 1450±50 r/min Pilot air jet (P.A.J.) #150...

  • Page 91: Removal, Disassembly And Inspection

    4-3 FUEL AND LUBRICA TION SYSTEM REMOVAL, DISASSEMBLY AND INSPECTION ① ● Turn fuel cock to “OFF”position. ● Remove the accelerator pump cable ①. ● Remove the choke cable ②. ② ● Loosen the intake pipe bolts. ● Loosen the clamp screw.
  • Page 92 FUEL AND LUBRICA TION SYSTEM 4-4 ● Loosen the carburetor top ① and disconnect throttle valve. ● Remove throttle cable from the throttle valve ② and disconnect throttle cable. ② ① ● Disconnect throttle valve spring and carburetor top from the throttle cable. ●...
  • Page 93 4-5 FUEL AND LUBRICA TION SYSTEM ● Disconnect fuel tube and drain tube. ACCELERATOR PUMP ● Loosen the screws and disconnect pump cover. ● Disconnect spring and diaphragm. ● Inspect the accelerator pump load and damage of diaphragm. ● Clean the diaphragm. ●...
  • Page 94 FUEL AND LUBRICA TION SYSTEM 4-6 FLOAT AND NEEDLE VALVE ● Loosen the screws and remove the float chamber. ● Pull out float arm pin ①. ● Remove the float ② and needle valve ③. ② ③ ① ● Inspect the needle valve and valve seat for wear. ●...

  • Page 95: Reassembly And Remounting

    4-7 FUEL AND LUBRICA TION SYSTEM ● Disconnect throttle stop screw ⑤. ● Clean the jets with non-flammable cleaning solvent. ● Check following items for damage or clogging. ∙ Main jet ∙ Pilot jet ∙ Pilot air screw ∙ Needle jet ⑤...
  • Page 96 FUEL AND LUBRICA TION SYSTEM 4-8 FLOAT ADJUSTMENT ● To check the float height, invert the carburetor body, holding the float arm pin so that the pin will not slip off. Float height 12.5 mm ● Check to be sure that the float moves freely. ●...
  • Page 97 4-9 FUEL AND LUBRICA TION SYSTEM ● Replace a new O-ring at the carburetor outlet side. ● Install the jet needle and retainer clip into the throttle valve. Leaner ※ Needle clip standard position : 3rd groove ↑ (Standard) ↓ Richer ●...
  • Page 98 FUEL AND LUBRICA TION SYSTEM 4-10 ● Install the carburetor between the cylinder and air cleaner out let tube, tighten the intake pipe bolts and clamp screw. ● Install the choke cable ①. ● Adjust play of throttle grip. (Refer to page 2-10) ①...

  • Page 99: Lubrication System

    4-11 FUEL AND LUBRICA TION SYSTEM LUBRICATION SYSTEM CAMSHAFT JOURNAL CONROD SMALL END AND CAM FACE CYLINDER WALL CAM CHAIN ROCKER ARM SHAFT CONROD BIG END BEARING CLUTCH RELEASE CAM COUNTERSHAFT BEARING DRIVESHAFT OIL FILTER BEARING COUNTERSHAFT BY-PASS AND GEARS OIL PUMP PRIMARY DRIVEN DRIVESHAFT...

  • Page 100: Electrical System

    ELECTRICAL SYSTEM CONTENTS IGNITION SYSTEM …………………………………………………………………… 5- 1 CHARGING SYSTEM…………………………………………………………………… 5- 5 STARTER SYSTEM …………………………………………………………………… 5- 9 SPEEDOMETER ASSY ………………………………………………………………… 5-12 LIGHTS ………………………………………………………………………………… 5-12 SWITCHES……………………………………………………………………………… 5-13 BATTERY ……………………………………………………………………………… 5-15...

  • Page 101: Ignition System

    5-1 ELECTRICAL SYSTEM IGNITION SYSTEM DESCRIPTION In the capacitor discharged ignition system, the electrical energy generated by the magento charges the capacitor. This ener- gy is released in a single surge at the specified ignition timing point, and current flows through the pirmary side of the igni- tion coil.
  • Page 102 ELECTRICAL SYSTEM 5-2 INSPECTION MAGNETO Using the pocket tester, measure the resistance between the lead wires in the following table. Pick-up coil Approx. 90-120Ω Power source Ⅰ Approx. 300-400Ω (HANKUK) Power source Ⅱ Approx. 400-600Ω (PUNG SUNG) Charging coil Approx. 0.5-1.5Ω 09900-25002 Pocket tester NOTE:...
  • Page 103 5-3 ELECTRICAL SYSTEM CDI UNIT ㏀ Using the pocket (R×1 range), measure the resistance between the lead wires in the following table. 09900-25002 Pocket tester � Probe of tester R/G Bl/R B/W B/Y OFF OFF WIRE COLOR ● ● ● ●...
  • Page 104 ELECTRICAL SYSTEM 5-4 IGNITION COIL RESISTANCE B-Ground Primary Approx. 0.5-1.5 Ω Plug cap-Ground Secondary Approx.4.7-5.57 ㏀ SPARK PLUG Clean the plug with a wire brush and pin. Use the pin to remove carbon, taking care not to damage the porcelain. ●...

  • Page 105: Charging System

    5-5 ELECTRICAL SYSTEM CHARGING SYSTEM DESCRIPTION The circuit of the charging system is indicated in figure, which is composed of an AC generator, regulator/rectifier unit and battery. The AC current generated from AC generator is converted by rectifier and is turned into DC current, then it charges the bat- tery.
  • Page 106 ELECTRICAL SYSTEM 5-6 when the engine r/min become higher, the generated voltage of AC generator also becomes higher and the voltage between points � and � of regulator becomes high according, and when it reaches the adjusted voltage of control unit, control unit becomes “ON”condition consequently.
  • Page 107 5-7 ELECTRICAL SYSTEM INSPECTION CHARGING OUTPUT CHECK Start the engine and keep it running at 5000r/min. Using the pocket tester, measure the DC voltage between the battery terminal � and �. If the tester reads under 13.5V or over 16.0V, check the AC generator no-load performance and regulator/rectifier.
  • Page 108 ELECTRICAL SYSTEM 5-8 REGULATOR/RECTIFIER Using the pocket tester (× 1Ω range), measure the resistance between the lead wires in the following table. If the resistance checked is incorrect, replace the regula- tor/rectifier. 09900-25002 Pocket tester Unit : Ω � Probe of tester W/Bl W/Bl 35-55...

  • Page 109: Starter System

    5-9 ELECTRICAL SYSTEM STARTER SYSTEM DESCRIPTION The starter system in shown in the diagram below : namely, the starter motor, relay, IG switch, starter button and battery. Depressing the starter button (on the right handlebar switch box) energizes the relay, causing the contact points to close which connects the starter motor to the battery.
  • Page 110 ELECTRICAL SYSTEM 5-10 STARTER MOTOR INSPECTION CARBON BRUSHES When the brushes are worn, the motor will be unable to produce sufficient torque, and the engine will be difficult to turn over. To prevent this, periodically, inspect the length of the brushes, replacing them when they are too short or chipping.
  • Page 111 5-11 ELECTRICAL SYSTEM STATER MOTOR REASSEMBLY BRUSH HOLDER AND HOUSING END When fixing brush holder to starter motor case, align the protrusion ① of the starter motor case with the notch ② of the brush holder. ① ② SECURING SCREWS Apply therad lock “1342”to starter motor securing screws.

  • Page 112: Speedometer Assy

    ELECTRICAL SYSTEM 5-12 SPEEDOMETER ASSY Remove the speedometer assy (See page 6-16). Disassemble the speedometer assy as shown in the illus- tration. INSPECTION Using the pocket tester, check the continuity between lead wires in the following diagram. If the continuity measured is incorrect, replace the respec- tive part.

  • Page 113: Switches

    5-13 ELECTRICAL SYSTEM TURNSIGNAL LIGHT TAIL/BRAKE LIGHT SWITCHES Inspect each switch for continuity with the pocket tester referring to the chart. If it is found any abnormality, replace the respective switch assembly with new one. 99000-25002 Pocket tester IGNITION SWITCH STARTER SWITCH ○...
  • Page 114 ELECTRICAL SYSTEM 5-14 DIMMER SWITCH GEAR POSITION INDICATOR LIGHT SWITCH R/B G/L Y/L Br/R Ground ○ ○ ○ ○ ○ ○ ○ ○ Neutral ○ ○ TURN SIGNAL LIGHT SWITCH ○ ○ ○ ○ ○ ○ ○ ○ ● ○ ○...

  • Page 115: Battery

    5-15 ELECTRICAL SYSTEM BATTERY Battery SPECIFICATIONS Type designation 12M8-3B Breather pipe Capacity 12V 9AH/10HR Standard electrolyte S. G. 1.280 at 20℃(68℉) In fitting the battery to the motorcycle, connect the breather tube to the battery vent. INITIAL CHARGING Filling electrolyte Remove short sealed tube cap ①...
  • Page 116 ELECTRICAL SYSTEM 5-16 Servicing Visually inspect the surface of the battery container. If any signs of cracking or electrolyte or electolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, then this can be cleaned away with sandpaper.
  • Page 117 5-17 ELECTRICAL SYSTEM CAUTION: Constant-voltage charging, otherwise called “quick” charging, is not recommendable for it could shorten the life of the battery. 09900-28403 Hydrometer Hydrometer SERVICE LIFE 1.28 Lead oxide is applied to the poles plate of the battery 1.24 which will come off gradually during the service.

  • Page 118: Chassis

    CHASSIS CONTENTS FRONT WHEEL………………………………………………………………………… 6- 1 FRONT FORK ………………………………………………………………………… 6- 5 STEERING STEM ……………………………………………………………………… 6-14 FRONT BRAKE ………………………………………………………………………… 6-21 REAR WHEEL AND REAR BRAKE …………………………………………………… 6-29 REAR SWING ARM ………………………………………………………………… 6-37...

  • Page 119: Front Wheel

    6-1 CHASSIS FRONT WHEEL Tightening torque Item Nㆍm ㎏ㆍm � � 36-52 3.6-5.2 � 15-25 1.5-2.5 � REMOVAL AND DISASSEMBLY ● Support the machine by the center stand and jack or block. ● Pull out the cotter pin and remove the axle nut.
  • Page 120 CHASSIS 6-2 ● Draw out the axle shaft and take off the front wheel. NOTE: Do not operate the front brake lever while dismounting the front wheel. ● Unlock the washers and remove the four bolts. ● Separate the disc plate from the wheel. CAUTION: Do not reuse the lock washers.
  • Page 121 6-3 CHASSIS AXLE SHAFT Using the special tools, check the axle shaft for runout and replace it if the runout exceeds the limit. 09900-20606 Dial gauge (1/100) 09900-20701 Magnetic stand 09900-21304 V-block (100mm) Service 0.25mm WHEEL RIM Make sure that the wheel rim runout does not exceed the service limit when checked as shown.

  • Page 122: Wheel Bearing

    CHASSIS 6-4 REASSEMBLY Reassemble and remount the front wheel in the reverse order of disassembly and removal, and also carry out the following steps : WHEEL BEARING ● Apply grease to the bearing before installing. 99000-07000 Grease “G ” ● Install the wheel bearings by using the special tool. 09913-75820 Bearing installer BRAKE DISC...

  • Page 123: Speedometer Gear Box

    6-5 CHASSIS SPEEDOMETER GEAR BOX Before installing the speedometer gear box grease it and align groove ① on the wheel hub with two drive pawls ② on the speedometer gear box. ② ① 99000-07000 Grease “G ” FRONT FORK � Tightening torque Item Nㆍm...
  • Page 124 CHASSIS 6-6 REMOVAL AND DISASSEMBLY ● Removal the front wheel. (See page 6-1) ● Remove the two bolts and take off the front caliper. ● Remove the four bolts and take off the front fender. ● Remove the two upper clamp bolts by using the 6 mm hexagon wrench.
  • Page 125 6-7 CHASSIS ● Pull down right and left front forks. ● Loosen the fork bolt. ● Draw out the spacer and fork spring. ● Invert the fork and stroke it several times to remove the oil. ● Hold the fork inverted for a few minutes.
  • Page 126 CHASSIS 6-8 ● Remove damper rod bolt by using the special tools and 8mm hexagon wrench. 09900-00401 “L” type hexagon wrench(6mm) ● Remove the oil lock piece and damper rod with rebound spring. ● Separate the inner tube from the outer tube. ●...
  • Page 127 6-9 CHASSIS ● Remove the oil seal by using the special tool. 09913-50121 Oil seal remover CAUTION: The oil seal removed should be replaced with a new one. INSPECTION DAMPER ROD RING Inspect the damper rod for wear and damage. INNER TUBE AND OUTER TUBE Inspect the inner tube and outer tube sliding surfaces for any scuffing or flaws.
  • Page 128 CHASSIS 6-10 REASSEMBLY Reassemble and remount the front fork in the reverse order of disassembly and removal, and also carry the following steps : DAMPER ROD BOLT Apply Three Bond No. 1215 and Thread Lock Cement to Thread lock cement Three Bond “1215”...
  • Page 129 6-11 CHASSIS Hold the front vertical and adjust the fork oil level with the special tool. NOTE: When adjusting oil level, remove the fork spring and compress the inner tube fully. 09943-74111 Fork oil level gauge Oil level 185 mm FORK SPRING Upside When installing the fork spring, the close pitch end should...
  • Page 130 CHASSIS 6-12 ● Tighten the lower clamp bolts with specificed torque. Tightening torque 25-35N∙m(2.5-3.5kg∙m) ● Install the front fender. ● Tighten the caliper mounting bolts with specificed torque. Tightening torque 15-25N∙m(1.5-2.5kg∙m) ● Install the front wheel.
  • Page 131 6-13 CHASSIS SPEEDOMETER ASSY DISASSEMBLY ● Remove the speedometer cable. ● Loosen the head lamp lens screw. ● Disconnect the speedometer coupler. ● Loosen the bolts and remove the speedometer.

  • Page 132: Steering Stem

    CHASSIS 6-14 STEERING STEM � � � Tightening torque Item Nㆍm ㎏ㆍm � 35-55 3.5-5.5 � � 35-55 3.5-5.5 � 25-35 2.5-3.5 � 12-20 1.2-2.0 REMOVE AND DISASSEMBLY ● Remove the front wheel. (Refer to Page 6-1) ● Remove the front fender. (Refer to Page 6-6) ●...
  • Page 133 6-15 CHASSIS ● Disconnect the lead wire and remove the head lamp housing ①. ① ● Remove the steering head cover. ● Loosen the steering stem bolt and remove the front fork upper bracket ②. ② ● Loosen the steering nut.
  • Page 134 CHASSIS 6-16 ● Remove the steering stem. ● Remove the dust seal. ● Remove the upper outer race. ● Remove the upper and lower steel balls. Upper 22 pcs Number of balls Lower 18 pcs...
  • Page 135 6-17 CHASSIS ● Remove the outer race fitted on the steering stem. This can be done with a chisel. ● Dwaw out the two inner reces fitted to the top and bottom ends of the head pipe. INSPECTION Inspect and check the removed parts for the following abnormalities.
  • Page 136 CHASSIS 6-18 REASSEMBLY Reassemble and remount the steering stem in the reverse order of disassembly and removal, and also carry out the following steps: INNER RACES Press in the upper and lower inner races using the spe- cial tool. 09941-34513 Steering race installer STEEL BALL Apply grease to the upper and lower inner races when...
  • Page 137 6-19 CHASSIS ● Turn the steering stem right and left, lock-to-lock, five or six times to “seat”the steel ball bearings. ● Turn back the stem nut by 1/4-1/2 turn. NOTE: This adjustment will vary from motorcycle to motorcycle. ● Tighten the steering stem head bolt with specified torque.
  • Page 138 CHASSIS 6-20 TIGHTENING TORQUE ① ① Item Nㆍm ㎏ㆍm ② ① 35-55 3.5-5.5 ② ② 35-55 3.5-5.5 ③ 25-35 2.5-3.5 ③ ③...

  • Page 139: Front Brake

    6-21 CHASSIS FRONT BRAKE � � Tightening torque Item Nㆍm ㎏ㆍm � 0.5-0.8 � 0.5-0.8 � � 15-25 1.5-2.5...
  • Page 140 CHASSIS 6-22 BRAKE PAD REPLACEMENT ● Remove the caliper mounting bolts and take off the caliper. CAUTOIN: Do not operate the brake lever while dismounting the caliper. ● Push the piston and caliper holder all the way to the caliper when removing the pad. ●...
  • Page 141 6-23 CHASSIS CALIPER REMOVAL AND DISASSEMBLY ● Disconnect the brake hose from the caliper and catch the brake fluid in a suitable receptacle. ● Remove the caliper mounting bolts and take off the caliper. CAUTOIN: Never re-use the brake fluid left over from the last servicing and stored for long peri - ods.
  • Page 142 CHASSIS 6-24 ● Remove the caliper holer from the caliper. ● Place a rag over the piston to prevent popping up. Force out the piston by using air gun. CAUTOIN: Do not use high pressure air to prevent piston dam- age.
  • Page 143 6-25 CHASSIS PISTON Inspect the piston surface for any scratches or other damage. RUBBER PARTS Inspect the each rubber part for damage and wear. DISC ● Measure the disc thickness by using the micrometer. 09900-20205 Micrometer (0-25mm) Service limit 3.0 mm ●...
  • Page 144 CHASSIS 6-26 BRAKE PADS Wear condition of brake pads can be checked by observ- ing the red limit line marked on the pad. When the wear exceeds the limit line, replace the pad with new ones. CAUTION: R e p l a c e t h e b r a k e p a d w i t h a s e t , o t h e r w i s e b r a k i n g p e r f o r m a n c e w i l l...
  • Page 145 6-27 CHASSIS MASTER CYLINDER REMOVAL AND DISASSEMBLY ● Please a cloth underneath the union bolt on the mas- ter cylinder to catch spilled drops of brake fluid. Unscrew the union bolts and disconnect the brake hose from the master cylinder joint. CAUTION: I m m e d i a t e l y a n d c o m p l e t e l y w i p e o f f a n y brake fluid contacting any part of the motor -...
  • Page 146 CHASSIS 6-28 INSPECTION ● Inspect the master cylinder bore for any scratches or other damage. ● Inspect the piston and cup surface for scratches or other damage. ● Inspect the dust seal boot for wear or damage. REASSEMBLY Reassemble and remount the master cylinder in the reverse orders of disassembly and removal, and also carry out the following steps: CAUTION:...

  • Page 147: Rear Wheel And Rear Brake

    6-29 CHASSIS REAR WHEEL AND REAR BRAKE � � Tightening torque Item Nㆍm ㎏ㆍm � � 50-80 � 0.5-0.8 � 18-28 1.8-2.8 REMOVAL AND DISASSEMBLY ● Support the machine by the center stand. ● Remove the rear brake adjuster nut and disconnect the brake rod.
  • Page 148 CHASSIS 6-30 ● Remove the rear axle nut. ● Loosen the chain adjuster lock nut and adjuster bolt, right and left. ● Remove the drive chain. (See page 3-4) ● Draw out the axle shaft and take off the rear wheel. ●...
  • Page 149 6-31 CHASSIS ● Remove the oil seal. ● Remove the bearing with retainer from the mounting drum. ● Remove the cushion from the wheel. ● Remove the right and left side wheel bearings from the wheel. NOTE: Remove the left side bearing first makes the job easier.
  • Page 150 CHASSIS 6-32 ● Take off the brake shoes. ● Remove the cam lever nut and bolt. ● Pull off the brake cam shaft, waaher, O-ring and cam lever. INSPECTION Play WHEEL BEARING Play Inspect the wheel bearing for paly by hand.
  • Page 151 6-33 CHASSIS ● Rotate the inner race by hand to inspect whether abnormal noise occurs and it rotates smoothly. Replace the bearing if there are any defects. AXLE SHAFT Using the special tools, check the axle shaft for runout exceeds the limit. 09900-20606 Dial gauge (1/100) 09900-20701...
  • Page 152 CHASSIS 6-34 REAR BRAKE DRUM Measure the brake drum I.D. to determine the extent of wear and, if the limit is exceed by the wear noted, replace the drum, the value of this limit is indicated inside the drum. Service limit 130.7 mm BRAKE SHOE Check the brake shoes and decide whether it should be...

  • Page 153: Brake Cam

    6-35 CHASSIS ● Install the wheel bearing by using the special tool. NOTE: First install wheel bearing for right side. 09913-80112 Bearing installer MOUNTING DRUM ● Insert the bearing with retainer by using the special tool. 09913-80112 Bearing installer SPROCKET After tightening the four nuts to specification, bend the washers lock tabs.

  • Page 154: Mounting Drum

    CHASSIS 6-36 BRAKE CAM LEVER Install the brake cam lever and tighten the cam lever nut with specified torque. Tightening torque 5-8 N∙m(0.5-0.8kg∙m) Apply grease to the mounting drum as shown. 99000-07000 Grease “G ”...

  • Page 155: Rear Swing Arm

    6-37 CHASSIS REAR SWING ARM � � � Tightening torque Item Nㆍm ㎏ㆍm � 50-80 5.0-8.0 � 10-15 1.0-1.5 REMOVAL AND DISASSEMBLY ● Remove the rear wheel. (See page 6-29) ● Remove the two bolts and take off the chain case.
  • Page 156 CHASSIS 6-38 ● Remove the rear shock absorber nuts and take off the shock absorber units. ● Remove the swing arm pivot nut and draw out the shaft. ● Remove the swing arm. ● Pull out the cotter and remove the nut and bolt. ●...
  • Page 157 6-39 CHASSIS INSPECTION BUSHING Inspect the bushing for wear and damage. SWING ARM PIVOT SHAFT Using the special tools, check the pivot shaft for runout and replace it if the runout exceeds the limit. 09900-20606 Dial gauge (1/100) 09900-20701 Magnetic stand 09900-21304 V-block (100 mm) Service limit...

  • Page 158: Servicing Information

    SERVICING INFORMATION CONTENTS TROUBLESHOOTING ………………………………………………………………… 7- 1 SPECIAL TOOLS ……………………………………………………………………… 7- 8 TIGHTENING TORQUE ………………………………………………………………… 7-12 SERVING DATA………………………………………………………………………… 7-14 WIRE AND CABLE ROUTING ………………………………………………………… 7-20 WIRING DIAGRAM …………………………………………………………………… 7-21...

  • Page 159: Troubleshooting

    7-1 SERVICING INFORMA TION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start or is Compression too low hard to start. 1. Valve clearance out of adjustment. Adjust. 2. Worn valve guides or poor seating of valves. Repair or replace.

  • Page 160: Valve Stem

    SERVICING INFORMA TION 7-2 Remedy Complaint Symptom and possible causes Noisy engine. Noise seems to come from transmission 1. Gears worn or rubbing. Replace. 2. Badly worn splines. Replace. 3. Primary gears worn or rubbing. Replace. 4. Badly worn bearings. Replace.
  • Page 161 7-3 SERVICING INFORMA TION Complaint Symptom and possible causes Remedy Engine lacks power. 1. Loss of valve clearance. Adjust. 2. Weakened valve springs. Replace. 3. Valve timing out of adjustment. Adjust. 4. Worn piston ring or cylinder. Replace. 5. Poor seating of valves. Repair.
  • Page 162 SERVICING INFORMA TION 7-4 ELECTRICAL Complaint Remedy Symptom and possible causes No sparking or poor 1. Defective ignition coil. Replace. sparking. 2. Defective spark plug. Replace. 3. Defective pick up coil. Replace. 4. Defective CDI unit. Replace. Spark plug soon 1.
  • Page 163 7-5 SERVICING INFORMA TION BATTERY Complaint Remedy Symptom and possible causes “Sulfation”acidic 1. Not enough electrolyte. Add distilled water, if the battery has white powdery not been damaged and “sulfation” has not substance or spots advanced too far, and recharge. on surfaces of cell 2.
  • Page 164 SERVICING INFORMA TION 7-6 CHASSIS Complaint Remedy Symptom and possible causes Steering feels too 1. Steering stem nut overtightened. Adjust. heavy or stiff. 2. Worn bearing or race in steering stem. Replace. 3. Distorted steering stem. Replace. 4. Not enough pressure in tires. Adjust.
  • Page 165 7-7 SERVICING INFORMA TION BRAKES Complaint Remedy Symptom and possible causes Poor braking 1. Not enough brake fluid in the reservoir. Refill to level mark. (FRONT and REAR) 2. Air trapped in brake fluid circuit. Bleed air out. 3. Pads worn down. Replace.

  • Page 166: Special Tools

    SERVICING INFORMA TION 7-8 SPECIAL TOOLS ITEM PART No. PART NAME 09900-00401 “L” Type hexagon wrench set 09900-06107 Snap ring pliers(opening type) 09900-06108 Snap ring pliers(closing type) 09900-09003 Impact driver set 09900-20101 Vernier calipers(150㎜) 09900-20202 Micrometer(25-50㎜) 09900-20203 Micrometer(50-75㎜) 09900-20205 Micrometer(75-100㎜) 09900-20508 Cylinder gauge set 09900-20606...
  • Page 167 7-9 SERVICING INFORMA TION ITEM PART No. PART NAME 09924-84510 Bearing installer set 09930-30102 Rotor remover slide shaft 09930-30162 Rotor remover 09930-40113 Rotor and sprocket holder 09930-44511 Rotor holder 09940-14911 Steering stem nut socket wrench 09940-50112 Fork oil seal installer 09941-34513 Steering race installer 09941-74910...
  • Page 168 SERVICING INFORMA TION 7-10...
  • Page 169 7-11 SERVICING INFORMA TION...

  • Page 170: Tightening Torque

    SERVICING INFORMA TION 7-12 TIGHTENING TORQUE ENGINE ITEM Nㆍm ㎏∙m Cylinder head cover bolt 12-16 1.2-1.6 Camshaft holder nut 25-29 2.5-2.9 Camshaft sprocket center bolt 25-30 2.5-3.0 Cylinder head nut 0.6-0.8 Cylinder base nut 0.6-0.8 Magneto rotor nut 56-60 5.6-6.0 Primary drive gear nut / Oil pump drive gear nut 40-60 4.0-6.0...
  • Page 171 7-13 SERVICING INFORMA TION TIGHTENING TORQUE CHART For other bolt and nuts who's is not listed, refer to this chart: Conventional or “4”marked bolt “7”marked bolt Bolt Diameter (mm) N∙m kg∙m N∙m kg∙m 1.0 - 2.0 0.1 - 0.2 1.5 - 3.0 0.15 - 0.3 2.0 - 4.0 0.2 - 0.4...
  • Page 172 SERVICING INFORMA TION 7-14 SERVICE DATA VALVE+GUIDE Unit : ㎜ ITEM STANDARD LIMIT ф22 － Valve diam ф19 － － Valve lift － Valve clearance or tappet clearance IN.&EX. 0.10~0.13 － (when cold) 0.010~0.037 0.35 Valve guide to valve stem clearance 0.35 0.030~0.057 5.000~5.012...
  • Page 173 7-15 SERVICING INFORMA TION CYLINDER+PISTON+PISTON RING Unit : ㎜ ITEM STANDARD LIMIT Compression pressure 12.0~15.0㎏/㎠ 8.0㎏/㎠ Piston to cylinder clearance 0.120 0.050-0.060 57.000-57.015 Cylinder bore 57.080 56.945-56.960 56.880 Piston diam Measure st 15 from the skirt end 0.05 Cylinder distortion Aoorox.
  • Page 174 SERVICING INFORMA TION 7-16 OIL PUMP ITEM STANDARD LIMIT Oil pump reduction ratio 2.000(30/15) Oil pressure(at 60℃, 140℉) 0.4-0.6㎏/㎠(at 3000r/min) CLUTCH Unit : ㎜ ITEM STANDARD LIMIT Clutch cable play 1/4-1/2 turn back Clutch release screw Drive plate thickness 2.9-4.1 Driven plate thickness 1.6±0.05 Driven plate distortion...
  • Page 175 7-17 SERVICING INFORMA TION CARBURETOR ITEM SPECIFICATION Carburetor type PD 18F Bore size 24㎜ I.D. No 93BO Idle r/min 1450±50rpm Float height 12.5㎜ Main jet(M.J) #100 Main air jet(M.A.J) Jet needle(J.N) J29B Needle jet(N.J) J6TC-3rd Pilot jet(P.J) Throttle valve(T.V) By-pass(B.P) 2.9 ф1.0,ф0.9 Valve seat(V.S) ф2.0㎜...
  • Page 176 SERVICING INFORMA TION 7-18 BRAKE+WHEEL Unit : ㎜ ITEM STANDARD LIMIT Front brake lever distance 5-20 Rear brake pedal free travel 20-30 Rear brake pedal height Brake drum I.D Rear wheel 130.7 Brake lining thickness Rear wheel Brake disc thickness Front wheel 4.0±0.2 Brake disc runout...
  • Page 177 7-19 SERVICING INFORMA TION FUEL+OIL ITEM STANDARD LIMIT Gasoline used should be graded 85-95 octane or Fuel type highter. An unleaded or low-lead type is recommended reserve 13.7ℓ Fuel tank including reserve 1.6ℓ Engine oil type SAE 10W/40, SF Change 850㎖...

  • Page 178: Wire And Cable Routing

    SERVICING INFORMA TION 7-20 WIRE AND CABLE ROUTING...

  • Page 179: Wiring Diagram

    7-21 SERVICING INFORMA TION WIRING DIAGRAM...
  • Page 180 Prepared by HYOSUNG MOTORS & MACHINERY INC. 1st Ed. Jun, 1997 Manual No. 99000-94200 Printed in Korea...

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